Avalon-Limited-2009.pdf

2009 ENGINE
Engine Mechanical (2GR-FE) - Avalon
ENGINE
ON-VEHICLE INSPECTION
1. INSPECT VALVE LASH ADJUSTER NOISE
a. Rev up the engine several times. Check that the engine does not emit unusual noises.
If unusual noises occur, warm up the engine and idle it for over 30 minutes. Then repeat this
procedure.
HINT:
If any defects or problems are found during the inspection above, perform lash adjuster inspection
(See INSPECTION ).
2. INSPECT IGNITION TIMING
a. Warm up the engine.
b. Turn the ignitioin switch off.
c. When using the Techstream:
Check the ignition timing.
1. Connect the Techstream to the DLC3.
2. Turn the ignitioin switch on.
3. Turn the tester on.
4. Enter DATA LIST MODE with the Techstream.
Ignition timing: 8 to 12° BTDC at idle
HINT:
Refer to the Techstream operator's manual for help on selecting the DATA LIST.
Run the engine at 1000 to 1300 rpm for 5 seconds, and then check that the engine rpm
returns to idle speed.
d. When not using the Techstream:
NOTE: When checking the ignition timing, the transmission should be
in the neutral position.
2009 Toyota Avalon Limited
2009 ENGINE Engine Mechanical (2GR-FE) - Avalon
domingo, 8 de diciembre de 2019 11:58:22 p. m. Page 1 © 2011 Mitchell Repair Information Company, LLC.

Check the ignition timing.
1. Using SST, connect terminals 13 (TC) and 4 (CG) of the DLC3.
SST 09843-18040
2. Remove the V-bank cover.
3. Pull out the red lead wire harness.
4. Connect the tester terminal of the timing light to the red lead wire as shown in the
illustration.
5. Check the ignition timing at idle.
Ignition timing: 8 to 12° BTDC at idle
NOTE: l Confirm the terminal numbers before connecting them.
Connection with a wrong terminal can damage the engine.
l Turn off all electrical systems before connecting the
terminals.
l Perform this inspection after the cooling fan motor is
turned off.
Fig. 1: Identifying DLC3 Connector Terminal CG And TC
Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.
NOTE: Use a timing light which detects the first signal.
NOTE: When checking the ignition timing, the transmission should be

Fig. 2: Identifying Red Lead Wire And Tester Terminal
HINT:
Run the engine at 1000 to 1300 rpm for 5 seconds, and then check that the engine rpm
returns to idle speed.
6. Disconnect terminals 13 (TC) and 4 (CG) of the DLC3.
7. Check the ignition timing at idle.
Ignition timing: 5 to 15 BTDC at idle
8. Confirm that the ignition timing moves to the advanced angle side when the engine rpm is
increased.
9. Remove the timing light.
3. INSPECT ENGINE IDLE SPEED
a. Warm up the engine.
b. When using the Techstream:
Check the idle speed.
1. Connect the Techstream to the DLC3.
2. Enter DATA LIST MODE with the Techstream.
Idle speed: 600 to 700 rpm
HINT:
NOTE: l When checking the idle speed, the transmission should be
l Check the idle speed with the cooling fan off.
l Switch off all accessories and air conditioning before
connecting the Techstream.

Refer to the Techstream operator's manual for further details.
c. When not using the Techstream:
Check the idle speed.
1. Using SST, connect tachometer test probe to terminal 9 (TAC) of the DLC3.
SST 09843-18030
2. Check the idle speed.
Idle speed: 600 to 700 rpm
Fig. 3: Identifying DLC3 Connector Terminal
4. INSPECT COMPRESSION
a. Warm up and stop the engine.
b. Disconnect the injector connectors.
c. Remove the intake air surge tank (See REMOVAL ).
d. Remove the 6 ignition coils.
e. Remove the 6 spark plugs.
f. Check the cylinder compression pressure.
1. Insert a compression gauge into the spark plug hole.
2. While cranking the engine, measure the compression pressure.
Compression pressure: 1.3 MPa (13 kgf/cm2 , 189 psi)
Minimum pressure: 0.98 MPa (10 kgf/cm2 , 142 psi)
Difference between each cylinder: 0.1 MPa (1.0 kgf/cm2 , 15 psi)

Fig. 4: Inserting Compression Gauge Into Spark Plug Hole
3. If the cylinder compression is low, pour a small amount of engine oil into the cylinder
through the spark plug hole and inspect again.
HINT:
l If adding oil increases the compression, the piston rings and / or cylinder bore may be
worn or damaged.
l If pressure stays low, a valve may be stuck or seated improperly, or there may be
leakage in the gasket.
5. INSPECT CO/HC
a. Start the engine.
b. Rev the engine at 2500 rpm for approximately 180 seconds.
c. Insert CO/HC meter testing probe at least 40 cm (1.3 ft) into the tailpipe during idling.
d. Check CO/HC concentration at idle and / or 2500 rpm.
HINT:
Check regulations and restrictions in your area when performing 2 mode CO/CH concentration
testing (engine check at both idle speed and at 2500 rpm).
If the CO/HC concentration does not comply with regulations, troubleshoot in the order given
below.
1. Check A/F sensor and heated oxygen sensor operation.
2. See the table below for possible causes, and then inspect and repair.
NOTE: l Always use a fully charged battery to obtain an engine
speed of 250 rpm or more.
l Check the other cylinders' compression pressure in the
same way.
l This measurement must be done as quickly as possible.

POSSIBLE CAUSES
DRIVE BELT
COMPONENTS
CO HC Problems Causes
Normal High Rough idle
1. Faulty ignitions:
¡ Incorrect timing
¡ Fouled, shorted or improperly
gapped plugs
2. Incorrect valve clearance
3. Leaks in intake and exhaust valves
4. Leaks in cylinders
Low High
Rough idle (fluctuating HC
reading)
1. Vacuum leaks:
¡ PCV hoses
¡ Intake manifold
¡ Throttle body
¡ Brake booster line
2. Lean mixture causing misfire
High High
Rough idle (black smoke from
exhaust)
1. Restricted air filter
2. Plugged PCV valve
3. Faulty SFI system:
¡ Faulty fuel pressure regulator
¡ Defective ECT sensor
¡ Defective MAF meter
¡ Faulty ECM
¡ Faulty injectors
¡ Faulty throttle position sensor

Fig. 5: Identifying Drive Belt Components (1 Of 2)

Fig. 6: Identifying Drive Belt Components (2 Of 2)
REMOVAL
1. REMOVE FRONT WHEEL RH
2. REMOVE FRONT FENDER APRON SEAL RH
3. REMOVE V-BANK COVER SUB-ASSEMBLY

4. REMOVE V-RIBBED BELT
a. Using SST, release the belt tension by turning the belt tensioner counterclockwise, and remove the
V-ribbed belt from the belt tensioner.
SST 09961-00950
Fig. 7: Identifying SST
b. While turning the belt tensioner counterclockwise, align with its holes, and then insert the 5 mm bi-
hexagon wrench into the holes to fix the V-ribbed belt tensioner.
Fig. 8: Inserting Bi-Hexagon Wrench Into Holes
INSPECTION
1. INSPECT V-RIBBED BELT
a. Visually check the V-ribbed belt for excessive wear, frayed cords, etc.
If any defect has been found, replace the V-ribbed belt.

HINT:
Cracks on the rib side of a V-ribbed belt are considered acceptable.
If the drive belt has chunks missing from its ribs, it should be replaced.
HINT:
l After installing the V-ribbed belt, check that it fits properly in the ribbed grooves. Check to
confirm that the belt has not slipped out of the grooves on the bottom of the crank pulley by
hand.
l A "new belt" is a belt which has been used for less than 5 minutes with the engine running.
l A "used belt" is a belt which has been used for 5 minutes or more with the engine running.
Fig. 9: Checking V-Ribbed Belt For Excessive Wear
l After installing a new belt, run the engine for approximately 5 minutes and then recheck the
tension.
2. INSPECT V-RIBBED BELT TENSIONER ASSEMBLY
a. Check that nothing gets caught in the tensioner by turning it clockwise and counterclockwise. If a
malfunction exists, replace the tensioner.
INSTALLATION
1. INSTALL V-RIBBED BELT

a. Install the V-ribbed belt.
b. Using SST, turn the belt tensioner counterclockwise, remove the bar.
SST 09961-00950
Fig. 10: Identifying SST
c. If it is difficult to install the V-ribbed belt, perform the following procedure.
1. Put the V-ribbed belt on everything except the tensioner pulley as shown in the illustration.
2. While releasing the belt tension by turning the belt tensioner counterclockwise, put the V-
ribbed belt on the tensioner pulley.
2. INSTALL V-BANK COVER SUB-ASSEMBLY
3. INSTALL FRONT FENDER APRON SEAL RH
4. INSTALL FRONT WHEEL RH
Torque: 103 N*m (1050 kgf*cm, 76 ft.*lbf)
NOTE: l Put the backside of the V-ribbed belt on the tensioner
pulley and idler pulley.
l Check that the V-ribbed belt is properly set to each pulley.

Fig. 11: View Of Drive Belt Routing
ENGINE FRONT OIL SEAL
COMPONENTS

Fig. 12: Identifying Engine Front Oil Seal Components (1 Of 3) View Of Drive Belt And Pulley

Fig. 13: Identifying Engine Front Oil Seal Components (2 Of 3)

Fig. 14: Identifying Engine Front Oil Seal Components (3 Of 3)
REMOVAL
1. REMOVE FRONT WHEEL RH

3. REMOVE V-BANK COVER SUB-ASSEMBLY
4. REMOVE FAN AND GENERATOR V BELT
HINT:
Remove V-ribbed belt (See REMOVAL ).
5. REMOVE CRANKSHAFT PULLEY (See DISASSEMBLY )
6. REMOVE TIMING CHAIN COVER OIL SEAL
a. Using a screwdriver, pry out the oil seal.
Fig. 15: Identifying Protective Tape Applying Area
INSTALLATION
1. INSTALL TIMING CHAIN COVER OIL SEAL
a. Apply MP grease to a new oil seal lip.
b. Using SST and a hammer, tap in the oil seal until its surface is flush with the timing chain cover
edge.
SST 09316-60011 (09316-00011)
2. INSTALL CRANKSHAFT PULLEY (See REASSEMBLY )
3. INSTALL FAN AND GENERATOR V BELT
HINT:
Install the V-ribbed belt (See INSTALLATION ).
NOTE: Be careful not to damage the crankshaft. Tape the screwdriver tip
before use.

Fig. 16: Identifying Chain Cover
4. INSTALL V-BANK COVER SUB-ASSEMBLY
5. INSTALL FRONT WHEEL RH
ENGINE REAR OIL SEAL
COMPONENTS

Fig. 17: Identifying Engine Rear Oil Seal Components (1 Of 3)

REMOVAL
1. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY
See REMOVAL
2. REMOVE DRIVE PLATE AND RING GEAR OR FLYWHEEL
a. Using SST, hold the crankshaft.
SST 09213-70011 (09213-70020), 09330-00021

Fig. 20: Holding Crankshaft
b. Remove the 8 bolts, front spacer, drive plate and rear spacer.
Fig. 21: Locating Front Spacer, Drive Plate And Rear Spacer Bolts
3. REMOVE ENGINE REAR OIL SEAL
a. Using a knife, cut off the oil seal lip.
b. Using a screwdriver, pry out the oil seal.
Fig. 22: Cutting Off Oil Seal Lip
NOTE: Be careful not to damage the crankshaft. Tape the screwdriver tip
before use.

INSTALLATION
1. INSTALL ENGINE REAR OIL SEAL
a. Apply MP grease to a new oil seal lip.
b. Using SST and a hammer, tap in the oil seal.
SST 09223-15030, 09950-70010 (09951-07150)
Oil seal tap in depth: -0.5 to 0.5 mm (-0.020 to 0.020 in.)
Fig. 23: Tapping In Oil Seal
2. INSTALL DRIVE PLATE AND RING GEAR OR FLYWHEEL
a. Using SST, hold the crankshaft.
SST 09213-70011 (09213-70020), 09330-00021
Fig. 24: Holding Crankshaft
b. Apply adhesive to 2 or 3 threads of the mounting bolt end.

Adhesive: Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
Fig. 25: Applying Adhesive To Threads Of Mounting Bolt End
1. Install the front spacer, drive plate and rear spacer on the crankshaft.
2. Install and tighten the 8 mounting bolts uniformly in several steps.
3. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY
See INSTALLATION
Fig. 26: Locating Mounting Bolts
ENGINE ASSEMBLY
COMPONENTS

Fig. 27: Identifying Engine Assembly Components With Torque Specification (1 Of 9)

Fig. 32: Identifying Engine Assembly Components With Torque Specification 6 Of 9)

REMOVAL

1. DISCHARGE FUEL SYSTEM PRESSURE
See PRECAUTION
2. REMOVE FRONT WHEELS
3. REMOVE ENGINE UNDER COVER RH
4. REMOVE ENGINE UNDER COVER LH
6. DRAIN ENGINE OIL
7. DRAIN ENGINE COOLANT (See REPLACEMENT )
8. DRAIN AUTOMATIC TRANSAXLE FLUID (See REMOVAL )
9. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH (See REMOVAL )
10. REMOVE WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH (See REMOVAL )
11. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (See REMOVAL )
12. REMOVE WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (See REMOVAL )
13. REMOVE COWL TOP PANEL OUTER (See REMOVAL )
14. REMOVE BATTERY
15. REMOVE COOL AIR INTAKE DUCT SEAL
a. Remove the 6 clips and intake duct seal.
16. REMOVE V-BANK COVER SUB-ASSEMBLY (See REMOVAL )
17. REMOVE V-RIBBED BELT (See REMOVAL )
18. REMOVE RADIATOR RESERVE TANK ASSEMBLY
Fig. 36: Locating Intake Duct Seal Clips
19. REMOVE NO. 2 ENGINE MOUNTING STAY RH
a. Remove the bolt, 2 nuts and No. 2 engine mounting stay RH.

Fig. 37: Locating Engine Mounting Stay Bolt And Nut RH
20. REMOVE ENGINE MOVING CONTROL ROD
a. Remove the 4 bolts and engine moving control rod.
Fig. 38: Locating Engine Moving Control Rod Bolts
21. REMOVE NO. 2 AIR CLEANER INLET
a. Disconnect the clamp and 2 vacuum hoses.
b. Remove the 2 bolts and No. 2 air cleaner inlet.
22. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE (See REMOVAL )
23. REMOVE AIR CLEANER CASE
a. Remove the air cleaner filter element from the air cleaner case.

Fig. 39: Locating Air Cleaner Filter Element From Air Cleaner Case And Bolts
b. Disconnect the connector, vacuum hose, and hose clamp.
c. Remove the 3 bolts and air cleaner case.
Fig. 40: Locating Air Cleaner Case Bolts
24. REMOVE NO. 1 AIR CLEANER INLET
a. Remove the bolt and No. 1 air cleaner inlet.

Fig. 41: Locating No.1 Air Cleaner Inlet
25. REMOVE INTAKE AIR RESONATOR SUB-ASSEMBLY
a. Disconnect the wire harness clamp.
b. Remove the clip, bolt and intake air resonator.
Fig. 42: Locating Intake Air Resonator Clip And Bolt
26. REMOVE NO. 1 FUEL VAPOR FEED HOSE
a. Remove the clamp and disconnect the No. 1 fuel vapor feed hose.
27. REMOVE INTAKE AIR SURGE TANK ASSEMBLY (See REMOVAL )
Fig. 43: Locating No. 1 Fuel Vapor Feed Hose Clamp

28. SEPARATE FUEL TUBE SUB-ASSEMBLY
a. Release the claw and remove the No. 1 fuel pipe clamp.
Fig. 44: Locating No. 1 Fuel Pipe Clamp Claw
b. Disconnect the connector from the tube while pinching parts A with your fingers as shown in the
illustration.
29. REMOVE RADIATOR HOSE INLET
a. Remove Identifying the clamp and disconnect the radiator hose inlet.
NOTE: l Check for contamination in the pipe and around the connector.
Clean if necessary and then disconnect the connector.
l Disconnect the connector by hand.
l Do not bend, kink or twist the nylon tube.
l If the pipe and connector are stuck together, push and pull on
the connector to release them.
l Put the pipe and connector ends in vinyl bags to prevent
damage and contamination.
Fig. 45: Disconnecting Connector From Tube

Fig. 46: Locating Radiator Hose Inlet Clamp
30. REMOVE RADIATOR HOSE OUTLET
a. Remove the clamp and disconnect the radiator hose outlet.
31. DISCONNECT NO. 1 OIL COOLER INLET HOSE (See REMOVAL )
32. DISCONNECT NO. 1 OIL COOLER OUTLET HOSE (See REMOVAL )
Fig. 47: Locating Radiator Hose Outlet Clamp
33. DISCONNECT HEATER WATER INLET HOSE A
a. Disconnect the heater water inlet hose.
34. DISCONNECT HEATER WATER OUTLET HOSE A
a. Disconnect the heater water outlet hose.
35. REMOVE ECM (See REMOVAL )
36. REMOVE STARTER ASSEMBLY (See REMOVAL )
37. REMOVE UPPER RELAY BLOCK COVER

Fig. 48: Locating Heater Water Outlet Hose
38. DISCONNECT ENGINE WIRE
a. Disconnect the engine wire from the engine room junction block.
1. Remove the nut and separate the wire harness.
2. Using a screwdriver, release the engine room junction block. Pull the engine room junction
block upward.
3. Disconnect the 2 engine wire connectors.
Fig. 49: Locating Engine Wire Connectors
b. Disconnect the engine wire connector and 3 clamps.
c. Remove the 2 bolts and disconnect the 2 ground cables.

Fig. 50: Locating Ground Cables Bolts
d. Remove the bolt and disconnect the ground cable from the wire bracket.
e. Disconnect the engine wire clamp.
f. Remove the 2 bolts and ground cable from the cylinder head.
39. SEPARATE WIRE HARNESS (See REMOVAL )
40. DISCONNECT CONNECTOR (See REMOVAL )
41. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (See REMOVAL )
Fig. 51: Locating Ground Cable Bracket Bolts
42. DISCONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE
a. Disconnect the No. 1 oil reservoir to pump hose.

Fig. 52: Locating No. 1 Oil Reservoir To Pump Hose
43. DISCONNECT STEERING GEAR OUTLET RETURN TUBE
a. Disconnect the steering gear outlet return tube.
44. REMOVE FRONT NO. 1 EXHAUST PIPE SUPPORT BRACKET (See REMOVAL )
45. REMOVE FRONT EXHAUST PIPE ASSEMBLY (See REMOVAL )
46. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH (See REMOVAL )
Fig. 53: Locating Steering Gear Outlet Return Tube
47. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH
HINT:
Use the same procedures described for the LH side.
48. REMOVE FRONT AXLE SHAFT LH NUT (See REMOVAL )
49. REMOVE FRONT AXLE SHAFT RH NUT
HINT:
50. SEPARATE FRONT SPEED SENSOR LH (See REMOVAL )

51. SEPARATE FRONT SPEED SENSOR RH
HINT:
52. SEPARATE TIE ROD ASSEMBLY LH (See REMOVAL )
53. SEPARATE TIE ROD ASSEMBLY RH
HINT:
54. DISCONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH (See
REMOVAL )
55. DISCONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH
HINT:
56. SEPARATE FRONT AXLE ASSEMBLY LH (See REMOVAL )
57. SEPARATE FRONT AXLE ASSEMBLY RH
HINT:
58. REMOVE NO. 1 EXHAUST PIPE SUPPORT BRACKET
a. Remove the nut and No. 1 exhaust pipe support bracket.
59. REMOVE FLYWHEEL HOUSING UNDER COVER (See REMOVAL )
60. REMOVE DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (See
REMOVAL )
61. DISCONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY (See REMOVAL )
62. REMOVE GENERATOR ASSEMBLY (See REMOVAL )
63. SEPARATE COOLER COMPRESSOR ASSEMBLY
a. Remove the 2 connector clamps.
b. Remove the 4 bolts and separate the compressor.
HINT:
Hang up the compressor and hoses instead of detaching them.
64. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE

a. Set the engine lifter.
Fig. 54: Locating Cooler Compressor Assembly Bolts
b. Remove the 4 bolts, 2 nuts, frame side rail plates RH and LH.
c. Remove the 4 bolts, 2 nuts, front suspension member brace rears RH and LH.
d. Operate the engine lifter, and then remove the engine assembly from the vehicle.
Fig. 55: Locating Frame Side Rail Plates RH And LH Bolts And Nuts
e. Install the 2 engine hangers with the 4 bolts as shown in the illustration.
Part NO.:
No. 1 engine hanger 12281-31120
No. 2 engine hanger 12282-31100
NOTE: Make sure that the engine is clear of all wiring and hoses.

Bolts 90119-A0117
f. Attach the engine sling device and hang the engine with the chain block.
Fig. 56: Locating Engine Hangers With Bolts
65. REMOVE VANE PUMP ASSEMBLY
a. Remove the pressure feed tube clamp bolt.
b. Remove the 2 bolts and vane pump.
Fig. 57: Locating Frame Side Rail Plates RH And LH Bolts
66. REMOVE FRONT FRAME ASSEMBLY
a. Disconnect the connector and clamp.

Fig. 58: Identifying Connector And Clamp
b. Disengage the 2 clamps.
Fig. 59: Locating Clamps
c. Remove the 2 nuts and disconnect the engine mounting insulators RH and LH.
Fig. 60: Locating Engine Mounting Insulators Bolts
d. Remove the bolt and disconnect the front engine mounting insulator.
67. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH (See REMOVAL )
68. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (See REMOVAL )
69. REMOVE ENGINE WIRE

70. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (See REMOVAL )
Fig. 61: Locating Front Engine Mounting Insulator Bolts
71. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (See REMOVAL )
72. INSTALL ENGINE STAND
a. Secure the engine onto an engine stand with the bolts.
73. REMOVE IGNITION COIL ASSEMBLY
a. Remove the 6 bolts and 6 ignition coils.
74. REMOVE NO. 2 ENGINE MOUNTING STAY RH
a. Remove the bolt and No. 2 engine mounting stay RH.
75. REMOVE INTAKE MANIFOLD
a. Uniformly loosen and remove the 6 bolts and 4 nuts.
b. Remove the intake manifold and 2 gaskets.
Fig. 62: Locating Intake Manifold Bolts And Nuts
76. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH
a. Uniformly loosen and remove the 6 nuts.
b. Remove the manifold and gasket.

Fig. 63: Locating Exhaust Manifold Sub-Assembly Nuts
77. REMOVE OIL LEVEL GAUGE GUIDE SUB-ASSEMBLY
a. Remove the oil level gauge.
b. Remove the 2 bolts, No. 1 oil level gauge guide and No. 2 oil level gauge guide.
c. Remove the 2 O-rings from the oil level gauge guides.
Fig. 64: Locating No. 1 Oil Level Gauge Guide And No. 2 Oil Level Gauge Guide Bolts
78. REMOVE NO. 2 MANIFOLD STAY
a. Remove the bolt, nut and No. 2 manifold stay.
Fig. 65: Locating No. 2 Manifold Stay Bolt And Nut

79. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
a. Remove the 3 bolts and No. 2 exhaust manifold heat insulator.
Fig. 66: Locating No. 2 Exhaust Manifold Heat Insulator With Bolts
80. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH
a. Uniformly loosen and remove the 6 nuts.
b. Remove the manifold and gasket.
Fig. 67: Locating Exhaust Manifold Sub-Assembly LH Nuts
81. REMOVE ENGINE MOUNTING BRACKET RH
a. Remove the 3 bolts and engine mounting bracket RH.

Fig. 68: Locating Engine Mounting Bracket RH Bolts
82. REMOVE DRIVE SHAFT BEARING BRACKET
a. Remove the 3 bolts and drive shaft bearing bracket.
Fig. 69: Locating Drive Shaft Bearing Bracket Bolts
83. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
a. Remove the 5 bolts and V-ribbed belt tensioner assembly.
Fig. 70: Locating Ribbed Belt Tensioner Assembly Bolts
84. REMOVE NO. 2 TIMING GEAR COVER
a. Remove the 2 bolts and No. 2 timing gear cover.

Fig. 71: Locating No. 2 Timing Gear Cover Bolts
85. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY
a. Remove the bolt, 2 plates and No. 2 idler pulley sub-assembly.
HINT:
Plate diameter: Idler pulley cover plate: 33.6 mm (1.32 in.) No. 2 idler pulley cover plate: 37.8 mm
(1.49 in.)
Fig. 72: Locating No. 2 Idler Pulley Sub-Assembly Bolts
86. REMOVE WATER PUMP PULLEY (See REMOVAL )
87. REMOVE FRONT NO. 1 ENGINE MOUNTING BRACKET LH
a. Remove the 6 bolts and front No. 1 engine mounting bracket LH.

Fig. 73: Locating Front No. 1 Engine Mounting Bracket LH. Bolts
88. REMOVE RADIO SETTING CONDENSER
a. Remove the 2 bolts and 2 radio setting condensers.
Fig. 74: Locating Radio Setting Condensers And Bolts
89. REMOVE NO. 1 VACUUM SWITCHING VALVE ASSEMBLY
a. Remove the bolt and No. 1 vacuum switching valve.

Fig. 75: Locating No. 1 Vacuum Switching Valve Bolt
90. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY
a. Using a 24 mm deep socket wrench, remove the engine oil pressure switch assembly.
91. REMOVE KNOCK CONTROL SENSOR (See REMOVAL )
Fig. 76: Removing/Installing Engine Oil Pressure Switch Assembly
92. REMOVE ENGINE COOLANT TEMPERATURE SENSOR
a. Using a 19 mm deep socket wrench, remove the engine coolant temperature sensor and gasket.
93. REPLACE PARTIAL ENGINE ASSEMBLY
Fig. 77: Removing/Installing Engine Coolant Temperature Sensor

INSTALLATION
1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR
a. Using a 19 mm deep socket wrench, install the engine coolant temperature sensor and a new gasket.
2. INSTALL KNOCK CONTROL SENSOR (See INSTALLATION )
Fig. 78: Removing/Installing Engine Coolant Temperature Sensor
3. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY
a. Clean the threads of the oil pressure switch. Apply adhesive to 2 or 3 threads of the oil pressure
switch.
Adhesive: Toyota Genuine Adhesive 1344, Three Bond 1344 or equivalent
b. Using a 24 mm deep socket wrench, install the oil pressure switch.
Fig. 79: Removing/Installing Engine Oil Pressure Switch Assembly
4. INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY

a. Install the No. 1 vacuum switching valve with the bolt.
Fig. 80: Locating No. 1 Vacuum Switching Valve Bolt
5. INSTALL RADIO SETTING CONDENSER
a. Install the 2 radio setting condensers with the 2 bolts.
Fig. 81: Locating Radio Setting Condensers And Bolts
6. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH

a. Install the front No. 1 engine mounting bracket LH with the 6 bolts.
7. INSTALL WATER PUMP PULLEY (See INSTALLATION )
Fig. 82: Locating Front No. 1 Engine Mounting Bracket LH. Bolts
8. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY
a. Install the bolt, 2 plates and No. 2 idler pulley sub-assembly.
HINT:
Plate diameter: Idler pulley cover plate: 33.6 mm (1.32 in.) No. 2 idler pulley cover plate: 37.8 mm
(1.49 in.)

Fig. 83: Locating No. 2 Idler Pulley Sub-Assembly Bolts
9. INSTALL NO. 2 TIMING GEAR COVER
a. Install the No. 2 timing gear cover with the 2 bolts.
Torque: 6.0 N*m (61 kgf*cm, 53 in.*lbf)
Fig. 84: Locating No. 2 Timing Gear Cover Bolts
10. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
a. Temporarily install the V-ribbed belt tensioner with the 5 bolts.
HINT:
Each bolt length is as follows:
A. 70 mm (2.76 in.)
B. 33 mm (1.30 in.)
b. Install the V-ribbed belt tensioner by tightening bolt 1 and bolt 2 in the order shown in the
illustration.
c. Tighten the other bolts.

Fig. 85: Identifying V-Ribbed Belt Tensioner Assembly
11. INSTALL DRIVE SHAFT BEARING BRACKET
a. Install the drive shaft bearing bracket with the 3 bolts.
Fig. 86: Locating Drive Shaft Bearing Bracket With Bolts
12. INSTALL ENGINE MOUNTING BRACKET RH
a. Install the engine mounting bracket RH with the 3 bolts.
Fig. 87: Locating Engine Mounting Bracket RH With Bolts

13. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH
a. Install a new gasket as shown in the illustration.
Fig. 88: Identifying Exhaust Manifold Sub-Assembly LH Gasket
b. Install the exhaust manifold sub-assembly LH with the 6 nuts.
Fig. 89: Locating Exhaust Manifold Sub-Assembly LH With Nuts
14. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
a. Install the No. 2 exhaust manifold heat insulator with the 3 bolts.

Fig. 90: Locating No. 2 Exhaust Manifold Heat Insulator With Bolts
15. INSTALL NO. 2 MANIFOLD STAY
a. Install the No. 2 manifold stay with the bolt and nut.
Fig. 91: Locating No. 2 Manifold Stay With Bolt And Nut
16. INSTALL OIL LEVEL GAUGE GUIDE SUB-ASSEMBLY
a. Install 2 new O-rings to the oil level gauge guides.
b. Apply a light coat of engine oil to the O-rings.
c. Push in the oil level gauge guide end into the guide hole.
d. Install the No. 1 oil level gauge guide with the bolt.
e. Install the No. 2 oil level gauge guide with the bolt.
f. Install the oil level gauge.

Fig. 92: Locating No. 1 Oil Level Gauge Guide And No. 2 Oil Level Gauge Guide Bolts
17. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
a. Install a new gasket as shown in the illustration.
Fig. 93: Identifying Exhaust Manifold Sub-Assembly RH Gasket
b. Install the exhaust manifold sub-assembly RH with the 6 nuts.
18. INSTALL INTAKE MANIFOLD
TIGHTENING PARTS REFERENCE CHART
NOTE: DO NOT apply oil to the bolts listed below:
Tightening Parts
Intake Manifold and Cylinder Head Sub-assembly RH
Intake Manifold and Cylinder Head Sub-assembly LH

Fig. 94: Locating Exhaust Manifold Sub-Assembly Nuts
a. Set a new gasket on each cylinder head.
b. Set the intake manifold on the cylinder heads.
c. Install and tighten the 6 bolts and 4 nuts uniformly in several steps.
19. INSTALL NO. 2 ENGINE MOUNTING STAY RH
a. Install the No. 2 engine mounting stay RH with the bolt.
20. INSTALL IGNITION COIL ASSEMBLY
a. Install the 6 ignition coil assemblies with the 6 bolts.
Fig. 95: Locating Ignition Coil Assemblies With Bolts
NOTE: l Align the port holes of the gaskets and cylinder heads.
l Make sure that the gaskets are installed in the correct direction.

21. REMOVE ENGINE STAND
22. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (See INSTALLATION )
23. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (See INSTALLATION )
24. CONNECT CONNECTOR (See INSTALLATION )
25. INSTALL WIRE HARNESS (See INSTALLATION )
26. INSTALL ENGINE WIRE
27. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (See INSTALLATION )
28. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (See INSTALLATION )
29. INSTALL FRONT FRAME ASSEMBLY
a. Install the engine mounting insulators RH and LH with the 2 nuts.
Fig. 96: Locating Engine Mounting Insulators Bolts
b. Install the front engine mounting insulator with the bolt.
Fig. 97: Locating Front Engine Mounting Insulator Bolts
c. Connect the 2 clamps.

Fig. 98: Locating Clamps
d. Connect the connector and clamp.
Fig. 99: Identifying Connector And Clamp
30. INSTALL VANE PUMP ASSEMBLY
a. Install the vane pump with the 2 bolts.
b. Install the pressure feed tube clamp bolt.

Fig. 100: Locating Frame Side Rail Plates RH And LH Bolts
31. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
a. Set the engine assembly with transaxle on the engine lifter.
b. Install the engine assembly to the vehicle.
c. Install the frame side rail plates RH and LH with the 4 bolts and 2 nuts.
Torque: A
85 N*m (867 kgf*cm, 63 ft.*lbf)
B
32 N*m (329 kgf*cm, 24 ft.*lbf)
d. Install the front suspension member brace rears RH and LH with the 4 bolts and 2 nuts.
Torque: C
85 N*m (867 kgf*cm, 63 ft.*lbf)
D
32 N*m (329 kgf*cm, 24 ft.*lbf)
Fig. 101: Locating Frame Side Rail Plates Bolts And Nuts
32. INSTALL COOLER COMPRESSOR ASSEMBLY
a. Temporarily install the cooler compressor with the 4 bolts.

b. Install the compressor with the 4 bolts by tightening the bolts in the order shown in the illustration.
c. Install the 2 connector clamps.
33. INSTALL GENERATOR ASSEMBLY (See INSTALLATION )
34. INSTALL STEERING INTERMEDIATE SHAFT ASSEMBLY (See INSTALLATION )
Fig. 102: Locating Compressor Bolts
35. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (See
INSTALLATION )
36. INSTALL FLYWHEEL HOUSING UNDER COVER (See INSTALLATION )
37. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET
a. Install the No. 1 exhaust pipe support bracket with the nut.
38. INSTALL FRONT AXLE ASSEMBLY LH (See INSTALLATION )
39. INSTALL FRONT AXLE ASSEMBLY RH
HINT:
40. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH (See
INSTALLATION )
41. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH
HINT:
42. INSTALL TIE ROD ASSEMBLY LH (See INSTALLATION )

43. INSTALL TIE ROD ASSEMBLY RH
HINT:
44. INSTALL FRONT SPEED SENSOR LH (See INSTALLATION )
45. INSTALL FRONT SPEED SENSOR RH
HINT:
46. INSTALL FRONT AXLE SHAFT LH NUT (See INSTALLATION )
47. INSTALL FRONT AXLE SHAFT RH NUT
HINT:
48. INSTALL FRONT STABILIZER LINK ASSEMBLY LH (See INSTALLATION )
49. INSTALL FRONT STABILIZER LINK ASSEMBLY RH
HINT:
50. INSTALL FRONT EXHAUST PIPE ASSEMBLY (See INSTALLATION )
51. INSTALL FRONT NO. 1 EXHAUST PIPE SUPPORT BRACKET (See INSTALLATION )
52. CONNECT STEERING GEAR OUTLET RETURN TUBE
a. Connect the steering gear outlet return tube.
Fig. 103: Locating Steering Gear Outlet Return Tube

53. CONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE
a. Connect the No. 1 oil reservoir to pump hose.
54. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (See INSTALLATION )
55. CONNECT ENGINE WIRE
a. Install the ground cable to the cylinder head with the 2 bolts.
Fig. 104: Locating No. 1 Oil Reservoir To Pump Hose
b. Connect the engine wire clamp.
c. Install the ground cable with the bolt to the wire bracket.
Fig. 105: Locating Ground Cable Bracket Bolts
d. Install the 2 ground cables with the 2 bolts.
Torque: Bolt A
8.4 N*m (86 kgf*cm, 74 in.*lbf)
Bolt B

8.0 N*m (82 kgf*cm, 71 in.*lbf)
e. Connect the engine wire connector and 3 clamps.
Fig. 106: Locating Ground Cables With Bolts
f. Connect the wire to the engine room junction block. Then, install it with the nut and 2 connectors.
56. INSTALL UPPER RELAY BLOCK COVER
57. INSTALL STARTER ASSEMBLY (See INSTALLATION )
58. INSTALL ECM (See INSTALLATION )
Fig. 107: Locating Engine Room Junction Block
59. CONNECT HEATER WATER OUTLET HOSE A
a. Connect the heater water outlet hose.
60. CONNECT HEATER WATER INLET HOSE A

a. Connect the heater water inlet hose,
61. CONNECT NO. 1 OIL COOLER OUTLET HOSE (See INSTALLATION )
62. CONNECT NO. 1 OIL COOLER INLET HOSE (See INSTALLATION )
Fig. 108: Locating Heater Water Inlet Hose
63. INSTALL RADIATOR HOSE OUTLET
a. Install the clamp and connect the radiator hose outlet.
Fig. 109: Locating Radiator Hose Outlet Clamp
64. INSTALL RADIATOR HOSE INLET
a. Install the clamp and connect the radiator hose inlet.

Fig. 110: Locating Radiator Hose Inlet Clamp
65. CONNECT FUEL TUBE SUB-ASSEMBLY
a. Push in the fuel tube connector to the fuel pipe until the connector makes a "click" sound.
b. Engage the claw and install the No. 1 fuel pipe clamp.
66. INSTALL INTAKE AIR SURGE TANK ASSEMBLY (See INSTALLATION )
Fig. 112: Locating No. 1 Fuel Pipe Clamp
67. INSTALL NO. 1 FUEL VAPOR FEED HOSE
a. Install the clamp and connect the No. 1 fuel vapor feed hose.
NOTE: l Check for damage or contamination on the connected part of
the pipe.
l Check if the pipe and the connector are securely connected by
trying to pull them apart.
Fig. 111: Pushing Fuel Tube Connector To Fuel Pipe

Fig. 113: Locating No. 1 Fuel Vapor Feed Hose Clamp
68. INSTALL INTAKE AIR RESONATOR SUB-ASSEMBLY
a. Install the intake air resonator with the bolt and clip.
b. Connect the wire harness clamp.
Fig. 114: Locating Intake Air Resonator Clip And Bolt
69. INSTALL NO. 1 AIR CLEANER INLET
a. Install the No. 1 air cleaner inlet with the bolt.

Fig. 115: Locating No. 1 Air Cleaner Inlet With Bolt
70. INSTALL AIR CLEANER CASE
a. Install the air cleaner case with the 3 bolts.
b. Connect the connector, vacuum hose, and hose clamp.
c. Install the air cleaner filter element to the air cleaner case.
71. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE (See INSTALLATION )
Fig. 116: Locating Air Cleaner Case Bolts
72. INSTALL NO. 2 AIR CLEANER INLET
a. Install the No. 2 air cleaner inlet with the 2 bolts.
b. Connect the clamp and 2 vacuum hoses.

Fig. 117: Locating No. 2 Air Cleaner Inlet With Bolts
73. CONNECT VACUUM HOSES
Fig. 118: Vacuum Hoses Routing Diagram

74. INSTALL ENGINE MOVING CONTROL ROD
a. Temporarily install the engine moving control rod with the 4 bolts.
b. First install the bolts A, and then the remaining bolt B.
Fig. 119: Locating Engine Moving Control Rod With Bolts
75. INSTALL NO. 2 ENGINE MOUNTING STAY RH
a. Temporarily install the No. 2 engine mounting stay RH with the bolt.
b. Tighten the 2 nuts.
76. INSTALL RADIATOR RESERVE TANK ASSEMBLY
77. INSTALL V-RIBBED BELT (See INSTALLATION )
78. INSTALL BATTERY
NOTE: When disconnecting the cable, some systems need to be initialized after
the cable is reconnected (See INITIALIZATION ).

Fig. 120: Locating No. 2 Engine Mounting Stay RH With Bolt
79. INSTALL COWL TOP PANEL OUTER (See INSTALLATION )
80. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY (See INSTALLATION )
81. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (See INSTALLATION )
82. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY RH (See INSTALLATION )
83. INSTALL WINDSHIELD WIPER ARM AND BLADE ASSEMBLY LH (See INSTALLATION )
84. INSTALL FRONT WHEELS
85. ADD ENGINE OIL (See REPLACEMENT )
86. ADD ENGINE COOLANT (See REPLACEMENT )
87. ADD AUTOMATIC TRANSAXLE FLUID (See INSTALLATION )
88. ADD POWER STEERING FLUID
89. BLEED POWER STEERING SYSTEM (See INSTALLATION )
90. INSPECT FOR FUEL LEAK (See ON-VEHICLE INSPECTION )
91. INSPECT FOR OIL LEAK
92. INSPECT FOR ENGINE COOLANT LEAK (See REPLACEMENT )
93. INSPECT FOR EXHAUST GAS LEAK
94. INSPECT SHIFT LEVER POSITION (See ADJUSTMENT )
95. ADJUST SHIFT LEVER POSITION (See ADJUSTMENT )
96. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
HINT:
Adjust the front wheel alignment (See ADJUSTMENT ).
97. INSPECT IGNITION TIMING (See ON-VEHICLE INSPECTION )
98. INSPECT ENGINE IDLE SPEED (See ON-VEHICLE INSPECTION )
99. INSPECT CO/HC (See ON-VEHICLE INSPECTION )
100. INSTALL V-BANK COVER SUB-ASSEMBLY (See INSTALLATION )
101. INSTALL COOL AIR INTAKE DUCT SEAL
a. Install the intake duct seal with the 6 clips.
102. CHECK ABS SPEED SENSOR SIGNAL
a. Check the ABS speed sensor signal (See TEST MODE PROCEDURE ).

Fig. 121: Locating Intake Duct Seal Clips
ENGINE UNIT
COMPONENTS
NOTE: Bank 1 may also be known as RH side.
Bank 2 may also be known as LH side.

Fig. 122: Identifying Engine Unit Components With Torque Specifications (1 Of 10)

DISASSEMBLY

1. REMOVE OIL FILLER CAP SUB-ASSEMBLY
a. Remove the oil filler cap sub-assembly.
2. REMOVE SPARK PLUG
3. REMOVE OIL PAN DRAIN PLUG
a. Remove the drain plug and gasket.
Fig. 132: Locating Drain Plug And Gasket
4. REMOVE VENTILATION VALVE SUB-ASSEMBLY
a. Remove the ventilation valve sub-assembly.
Fig. 133: Locating Ventilation Valve Sub-Assembly
5. REMOVE CAMSHAFT POSITION SENSOR
a. Remove the 4 bolts and 4 camshaft position sensors.
CAUTION: For additional information on timing chain/gear removal guidelines,
installtion and camshaft timing gear alignment, see 2GR-FE VALVE
TIMING PROCEDURE .

Fig. 134: Locating Camshaft Position Sensors Bolts
6. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
a. Remove the 4 bolts and 4 camshaft timing oil control valves.

Fig. 135: Locating Camshaft Timing Oil Control Valves Bolts
7. REMOVE CRANK POSITION SENSOR
a. Remove the bolt and crankshaft position sensor.
Fig. 136: Locating Crankshaft Position Sensor Bolt
8. REMOVE OIL PIPE NO. 1
a. Remove the 2 oil pipe unions and oil pipe No. 1.
b. Remove the oil control valve filter LH and gaskets.
Fig. 137: Locating Oil Pipe Unions And Oil Pipe No. 1
9. REMOVE OIL PIPE
a. Remove the bolt.
b. Remove the 2 oil pipe unions and oil pipe.
c. Remove the oil control valve filter RH and gaskets.

Fig. 138: Locating Oil Pipe Unions And Oil Pipe Bolts
10. REMOVE CYLINDER BLOCK WATER DRAIN COCK SUB-ASSEMBLY
a. Remove the water drain cocks from the cylinder block.
b. Remove the water drain cock plugs from the water drain cocks.
Fig. 139: Locating Water Drain Cock Plugs From Water Drain Cocks
11. REMOVE OIL FILTER ELEMENT
a. Remove the drain plug.
NOTE: Do not remove the O-ring.

Fig. 140: Locating Drain Plug
b. Connect the hose to the pipe.
c. Insert the pipe with the hose into the oil filter cap.
d. Make sure that the oil is completely drained and remove the pipe and O-ring.
Fig. 141: Connecting Hose To Pipe
e. Using SST, remove the oil filter cap.
SST 09228-06501

Fig. 142: Removing Oil Filter Cap
f. Remove the oil filter element and O-ring from the oil filter cap.
Fig. 143: Identifying Oil Filter Element And O-Ring
12. REMOVE CRANKSHAFT PULLEY
a. Using SST, loosen the crankshaft pulley bolt.
SST 09213-70011 (09213-70020), 09330-00021
Fig. 144: Loosening Crankshaft Pulley Bolt
NOTE: Do not use any tools when removing the O-ring to prevent the O-ring
groove from being damaged.

b. Using SST, remove the crankshaft pulley bolt and crankshaft pulley.
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)
Fig. 145: Removing Crankshaft Pulley Bolt And Crankshaft Pulley
13. REMOVE ENGINE MOUNTING BRACKET FRONT NO. 1 LH
a. Remove the 6 bolts, and engine mounting bracket front No. 1 LH.
Fig. 146: Locating Engine Mounting Bracket Front No. 1 Bolts
14. REMOVE WATER INLET HOUSING
a. Remove the 2 nuts, water inlet and thermostat.
b. Remove the gasket.
c. Remove the drain cock plug.
d. Remove the drain cock.

Fig. 147: Locating Water Inlet Housing Nuts
e. Remove the 2 bolts, nut, and water inlet housing.
Fig. 148: Locating Water Inlet Housing Bolts And Nuts
f. Remove the 2 O-rings.
Fig. 149: Locating O-Rings
15. REMOVE WATER OUTLET
a. Remove the 2 bolts, 4 nuts, and water outlet.

Fig. 150: Locating Water Outlet Bolts And Nuts
b. Remove the 2 gaskets and O-ring.
Fig. 151: Locating Gaskets And O-Ring
16. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH
a. Remove the 12 bolts, head cover and gasket.
Fig. 152: Locating Head Cover And Gasket And Bolts
17. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
a. Remove the 12 bolts, head cover and gasket.

Fig. 153: Locating Head Cover And Gasket Bolts
18. REMOVE OIL PAN SUB-ASSEMBLY NO. 2
a. Remove the 16 bolts and 2 nuts.
Fig. 154: Locating Oil Pan Sub-Assembly No. 2 Bolts And Nuts
b. Insert the blade of SST between the oil pans. Cut through the applied sealer and remove the oil pan
sub-assembly No. 2.
SST 09032-00100
Fig. 155: Inserting Blade Of SST Between Oil Pans
NOTE: Be careful not to damage the contact surfaces of the oil pans.

19. REMOVE OIL STRAINER SUB-ASSEMBLY
a. Remove the bolt, 2 nuts, oil strainer and gasket.
Fig. 156: Locating Oil Strainer Sub-Assembly Bolts And Nuts
20. REMOVE OIL PAN SUB-ASSEMBLY
a. Remove the 16 bolts and 2 nuts.
HINT:
Be sure to clean the bolts and stud bolts and check the threads for cracks or other damage.
Fig. 157: Locating Oil Pan Sub-Assembly Bolts And Nuts
b. Remove the oil pan by prying between the oil pan and cylinder block with a screwdriver.
HINT:
Tape the screwdriver tip before use.
NOTE: Be careful not to damage the contact surfaces of the cylinder block
and oil pan.

c. Remove the 2 O-rings.
Fig. 159: Locating O-Rings
21. REMOVE OIL PAN BAFFLE PLATE NO.1
a. Remove the 7 bolts and oil pan baffle plate.
Fig. 160: Locating Oil Pan Baffle Plate Bolts

22. REMOVE ENGINE REAR OIL SEAL
a. Remove the 6 bolts.
Fig. 161: Locating Engine Rear Oil Seal Bolts
b. Using a screwdriver, pry out the oil seal retainer.
HINT:
Fig. 162: Prying Out Oil Seal Retainer
23. REMOVE WATER PUMP ASSEMBLY
a. Remove the 16 bolts, water pump and gasket.

Fig. 163: Locating Water Pump And Gasket Bolts
24. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY
a. Remove the 15 bolts and 2 nuts as shown in the illustration.
Fig. 164: Locating Timing Chain Cover Sub-Assembly Bolts And Nuts
b. Remove the timing chain cover by prying between the timing chain cover and cylinder head or
cylinder block with a screwdriver.
HINT:
c. Remove the 4 bolts, chain cover plate and gasket.
NOTE: Be careful not to damage the contact surfaces of the cylinder head,
cylinder block and chain cover.

Fig. 165: Locating Chain Cover Plate And Gasket Bolts
d. Remove the gasket.
Fig. 166: Identifying Gasket
25. SET NO. 1 CYLINDER TO TDC / COMPRESSION
a. Temporarily tighten the pulley set bolt.
b. Set the timing mark on the crank angle sensor plate to the RH block bore center line (TDC /
CAUTION: For additional information on timing chain/gear removal guidelines,
installtion and camshaft timing gear alignment, see 2GR-FE VALVE
TIMING PROCEDURE .

compression).
Fig. 167: Identifying Timing Mark On Crank Angle Sensor Plate
c. Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the
bearing cap as shown in the illustration.
If not, turn the crankshaft 1 revolution (360°) and align the timing marks as above.
Fig. 168: Identifying Timing Marks Of Camshaft Timing Gears

26. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY
a. Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.
b. Move the stopper plate downward to set the lock, and insert a hexagon wrench into the stopper
plate's hole.
c. Remove the 2 bolts and chain tensioner.
27. REMOVE CHAIN TENSIONER SLIPPER
a. Remove the chain tensioner slipper.
Fig. 169: Identifying Chain Tensioner Slipper
28. REMOVE CHAIN SUB-ASSEMBLY
a. Turn the crankshaft counterclockwise 10° to loosen the chain of the crankshaft timing gear.
b. Remove the chain from the crank timing gear and place it on the crankshaft.
Fig. 170: Identifying Chain Sub-Assembly
c. Turn the camshaft timing gear assembly on the RH bank clockwise (approximately 60°) and set it
as shown in the illustration. Be sure to loosen the chain between the center banks.
d. Remove the chain.

Fig. 171: Identifying Chain Sub-Assembly
29. REMOVE IDLE SPROCKET ASSEMBLY
a. Using a 10 mm hexagon wrench, remove the idle gear shaft No. 2, idle sprocket and idle gear shaft
No. 1.
Fig. 172: Locating Idle Sprocket Assembly
30. REMOVE NO. 1 CHAIN VIBRATION DAMPER
a. Remove the 2 bolts and chain vibration damper No. 1.
31. REMOVE NO. 2 CHAIN VIBRATION DAMPER
a. Remove the 2 chain vibration dampers.
Fig. 173: Locating Chain Vibration Dampers

32. REMOVE CRANKSHAFT TIMING GEAR
a. Remove the pulley set bolt.
b. Remove the crankshaft timing gear from the crankshaft.
c. Remove the 2 pulley set keys from the crankshaft.
Fig. 174: Identifying Crankshaft Timing Gear
33. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for RH BANK)
a. While raising up the chain tensioner No. 2, insert a pin of 1.0 mm (0.039 in.) into the hole to fix it.
Fig. 175: Inserting Pin Into Hole
b. Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts and 2 camshaft
timing gears.
c. Remove the No. 2 chain.
NOTE: l Be careful not to damage the cylinder head with the wrench.
l Do not disassemble the camshaft timing gear assembly.

Fig. 176: Holding Hexagonal Portion Of Camshaft
a. Remove the bolt and chain tensioner No. 2.
Fig. 177: Locating Chain Tensioner No. 2 Bolt
35. REMOVE CAMSHAFT BEARING CAP
a. Remove the 3 gaskets.
Fig. 178: Locating Camshaft Bearing Cap Gaskets
b. Make sure that the knock pin of the camshaft is positioned as shown in the illustration.

Fig. 179: Identifying Camshaft Positioned
c. Uniformly loosen and remove the 8 bearing cap bolts in the sequence shown in the illustration.
Fig. 180: Identifying Loosening Sequence Of Bearing Cap Bolts
d. Uniformly loosen and remove the 12 bearing cap bolts in the sequence shown in the illustration.
e. Remove the 5 bearing caps.
36. REMOVE CAMSHAFT
a. Remove the camshaft.
37. REMOVE NO. 2 CAMSHAFT
a. Remove the No. 2 camshaft.
NOTE: Uniformly loosen the bolts while keeping the camshaft level.

38. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH
a. Remove the camshaft housing sub-assembly RH by prying between the cylinder head and camshaft
housing sub-assembly RH with a screwdriver.
HINT:
NOTE: Be careful not to damage the contact surfaces of the cylinder head
and camshaft housing.

39. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for LH BANK)
a. While pushing down the chain tensioner No. 3, insert a pin of 1.0 mm (0.039 in.) into the hole to
fix it.
Fig. 183: Inserting Pin Into Hole
b. Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts and 2 camshaft
timing gears.
c. Remove the No. 2 chain.
Fig. 184: Holding Hexagonal Portion Of Camshaft
a. Remove the bolt and chain tensioner No. 3.
NOTE: l Be careful not to damage the cylinder head with the wrench.
l Do not disassemble the camshaft timing gear assembly.

Fig. 185: Locating Chain Tensioner No. 3 Bolt
41. REMOVE CAMSHAFT BEARING CAP
a. Remove the 3 gaskets.
Fig. 186: Locating Camshaft Bearing Cap Bolts
b. Make sure that the knock pin of the camshaft is positioned as shown in the illustration.
Fig. 187: Identifying Camshaft Position

c. Uniformly loosen and remove the 8 bearing cap bolts in the sequence shown in the illustration.
d. Uniformly loosen and remove the 13 bearing cap bolts in the sequence shown in the illustration.
e. Remove the 5 bearing caps.
44. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH
a. Remove the camshaft housing sub-assembly LH by prying between the cylinder head and camshaft
housing sub-assembly LH with a screwdriver.
NOTE: Uniformly loosen the bolts while keeping the camshaft level.
NOTE: Be careful not to damage the contact surfaces of the cylinder head
and camshaft housing.

HINT:
45. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
a. Remove the 24 valve rocker arms.
HINT:
Arrange the removed parts in the correct order.
46. REMOVE VALVE LASH ADJUSTER ASSEMBLY
a. Remove the 24 valve lash adjusters from the cylinder head.
HINT:
47. REMOVE CYLINDER HEAD LH
a. Uniformly loosen and remove the 2 bolts in the sequence shown in the illustration.

Fig. 191: Identifying Loosening Sequence Of Bolts
b. Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 bolts in the sequence shown in the
illustration. Remove the 8 cylinder head bolts and plate washers.
HINT:
Be sure to keep the removed parts separate for each installation position.
Fig. 192: Identifying Loosening Sequence Of Cylinder Head Bolts
c. Remove the cylinder head and gasket.
48. REMOVE CYLINDER HEAD SUB-ASSEMBLY
a. Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 bolts in the sequence shown in the
illustration. Remove the 8 cylinder head bolts and plate washers.
NOTE: l Be careful not to drop washers into the cylinder head.
l Head warpage or cracking could result from not removing bolts
in an incorrect order.
NOTE: l Be careful not to drop washers into the cylinder head.
l Head warpage or cracking could result from not removing bolts
in an incorrect order.

HINT:
Be sure to keep the removed parts separate for each installation position.
Fig. 193: Identifying Cylinder Head Sub-Assembly Bolts Loosening Sequence
b. Remove the cylinder head and gasket.
49. REMOVE WATER INLET PIPE
a. Separate the knock sensor wire.
b. Remove the 2 bolts and water outlet pipe.
c. Separate the water by-pass hose No. 1.
50. REMOVE VALVE STEM CAP
a. Remove the valve stem caps from the cylinder head.
HINT:
Fig. 194: Locating Water Outlet Pipe Bolts
51. REMOVE INTAKE VALVE
a. Using SST and wooden blocks, compress the compression spring and remove the valve retainer
locks.

SST 09202-70020 (09202-00010)
b. Remove the retainer, compression spring and valve.
HINT:
Fig. 195: Compressing Compression Spring
52. REMOVE EXHAUST VALVE
a. Using SST and wooden blocks, compress the compression spring and remove the valve retainer
locks.
SST 09202-70020(09202-00010)
b. Remove the retainer, compression spring and valve.
HINT:
Fig. 196: Compressing Compression Spring
53. REMOVE VALVE STEM OIL SEAL

a. Using needle-nose pliers, remove the oil seals.
Fig. 197: Removing Oil Seals
54. REMOVE VALVE SPRING SEAT
a. Using compressed air and a magnetic finger, remove the valve spring seat by blowing air onto it.
Fig. 198: Removing Valve Spring Seat By Blowing Air
55. REMOVE WITH HEAD STRAIGHT SCREW PLUG NO. 1
a. Using a 10 mm hexagon wrench, remove the 4 screw plugs and 4 gaskets.
NOTE: If water leaks from the w/ head straight screw plug No. 1 or the plug
is corroded, replace it.

Fig. 199: Removing Screw Plugs And Gaskets
56. REMOVE WITH HEAD STRAIGHT SCREW PLUG NO. 2
a. Using a 14 mm hexagon wrench, remove the 2 screw plugs and 2 gaskets.
57. REMOVE RING PIN
58. REMOVE STUD BOLT
NOTE: If water leaks from the w/ head straight screw plug No. 2 or the plug
is corroded, replace it.
NOTE: It is not necessary to remove the ring pin unless it is being replaced.
NOTE: If the stud bolt is deformed or the threads are damaged, replace it.

Fig. 200: Locating Screw Plugs
59. REMOVE STRAIGHT PIN
60. REMOVE PISTON SUB-ASSEMBLY WITH CONNECTING ROD
a. Using a ridge reamer, remove all the carbon from the top of the cylinder.
b. Push the piston, connecting rod assembly and upper bearing through the top of the cylinder block.
HINT:
l Keep the bearing, connecting rod and cap together.
l Arrange the piston and connecting rod assemblies in the correct order.
NOTE: If the straight pin is deformed or the threads are damaged, replace it.

Fig. 201: Removing Carbon From Top Of Cylinder
61. REMOVE CONNECTING ROD BEARING
HINT:
62. REMOVE CRANKSHAFT
a. Uniformly loosen and remove the 8 main bearing cap bolts and seal washers in the several steps
and in the sequence shown in the illustration.
Fig. 202: Identifying Crankshaft Main Bearing Cap Bolts Loosening Sequence
b. Uniformly loosen the 16 bearing cap bolts in several steps in the sequence shown in the illustration.

Fig. 203: Identifying Bearing Cap Bolts Loosening Sequence
c. Using a screwdriver, pry out main bearing caps. Remove the 4 main bearing caps and lower
bearings.
63. REMOVE CRANKSHAFT BEARING
HINT:
NOTE: l Pull up the main cap little by little to the right and the left in
turns.
l Be careful not to damage the joint surface of the cylinder block
and the main bearing caps.

Fig. 204: Prying Out Main Bearing Caps
64. REMOVE CRANKSHAFT THRUST WASHER SET
a. Remove the upper bearings and upper thrust washers from the cylinder block.
Fig. 205: Locating Upper Bearings And Upper Thrust Washers
65. REMOVE PISTON RING SET
a. Using a piston ring expander, remove the 2 compression rings.
b. Using a piston ring expander, remove the 2 side rails.
c. Remove the oil ring expander by hand.
HINT:

Arrange the piston rings in the correct order.
Fig. 206: Removing Side Rails
66. REMOVE PISTON SUB-ASSEMBLY WITH PIN
a. Check the fitting condition between the piston and piston pin.
1. Try to move the piston back and forth on the piston pin.
If any movement is felt, replace the piston and pin as a set.
Fig. 207: Checking Fitting Condition Between Piston And Piston Pin
b. Disconnect the connecting rod from the piston.
1. Using a screwdriver, pry off the snap rings from the piston.
Fig. 208: Prying Off Snap Rings From Piston

2. Gradually heat the piston to approximately 80°C (176°F).
Fig. 209: Heating Piston
3. Using a brass bar and plastic hammer, lightly tap out the piston pin and remove the
connecting rod.
HINT:
l The piston and pin are a matched set.
l Arrange the pistons, pins, rings, connecting rods and bearings in the correct order.
Fig. 210: Tapping Out Piston Pin
c. Using a gasket scraper, remove the carbon from the piston top.

Fig. 211: Removing Carbon From Piston Top
d. Using a groove cleaning tool or broken ring, clean the piston ring grooves.
Fig. 212: Cleaning Piston Ring Grooves
e. Using solvent and a brush, thoroughly clean the piston.
Fig. 213: Cleaning Piston
67. REMOVE SUB-ASSEMBLY OIL NOZZLE NO. 1
a. Using a 5 mm hexagon wrench, remove the 3 oil nozzles.
b. Check the oil nozzles for damage or clogging. If necessary, replace the oil nozzle.
NOTE: Do not use a wire brush.

INSPECTION
1. INSPECT VALVE LASH ADJUSTER ASSEMBLY
a. Place the lash adjuster into a container full of engine oil.
b. Insert SST's tip into the lash adjuster's plunger and use the tip to press down on the check ball
inside the plunger.
SST 09276-75010
c. Squeeze SST and lash adjuster together to move the plunger up and down 5 to 6 times.
d. Check the movement of the plunger and bleed the air.
OK: Plunger moves up and down.
e. After bleeding the air, remove SST. Then quickly and firmly press the plunger with a finger.
OK: Plunger is very difficult to move.
If the result is not as specified, replace the lash adjuster.
NOTE: l Keep the lash adjuster free from dirt and foreign objects.
l Only use clean engine oil.
Fig. 214: Locating Oil Nozzles
NOTE: When bleeding high-pressure air from the compression chamber,
make sure that the tip of SST is actually pressing the checkball as
shown in the illustration. If the checkball is not pressed, air will not
bleed.

Fig. 215: Inserting SST's Tip Into Lash Adjuster's Plunger
2. INSPECT CAMSHAFTS
a. Inspect camshaft for runout.
1. Place the camshaft on V-blocks.
2. Using a dial indicator, measure the circle runout at the center journal.
Maximum circle runout: 0.04 mm (0.0016 in.)
If the circle runout is greater than the maximum, replace the camshaft.
HINT:
Check the oil clearance after replacing the camshaft.

Fig. 216: Measuring Circle Runout At Center Journal
b. Using a micrometer, measure the cam lobe height.
Standard cam lobe height
CAM LOBE HEIGHT SPECIFICATION
Maximum cam lobe height
CAM LOBE HEIGHT SPECIFICATION
Fig. 217: Measuring Cam Lobe Height
c. Using a micrometer, measure the journal diameter.
Standard journal diameter
JOURNAL DIAMETER
Item Specification
Intake 44.316 to 44.416 mm (1.7447 to 1.7487 in.)
Exhaust 44.262 to 44.362 mm (1.7426 to 1.7465 in.)
Item Specification
Intake 44.166 mm (1.7388 in.)
Exhaust 44.112 mm (1.7367 in.)

If the journal diameter is not as specified, check the oil clearance.
Fig. 218: Measuring Journal Diameter
3. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY
a. Clamp the camshaft in a vise.
b. Put the camshaft timing gear and camshaft together by aligning the key groove and straight pin.
c. Lightly press the gear against the camshaft, and turn the gear. Push further at the position where the
pin enters the groove.
d. Check that there is no clearance between the gear's fringe and the camshaft.
Fig. 219: Aligning Key Groove And Straight Pin
Item Specification
No. 1 journal 35.946 to 35.960 mm (1.4152 to 1.4157 in.)
Other journal 25.959 to 25. 975 mm (1.0220 to 1.0226 in.)
NOTE: Be careful not to damage the camshaft in the vise.
CAUTION: Be sure not to turn the camshaft timing gear in the retard
direction (the right angle).

e. Tighten the fringe bolt with the camshaft timing gear fixed.
Torque: 100 N*m (1,020 kgf*cm, 74 ft.*lbf)
f. Check the lock of the camshaft timing gear.
1. Clamp the camshaft in a vise, and confirm that the camshaft timing gear is locked.
Fig. 220: Tightening Fringe Bolt With Camshaft Timing Gear
g. Release the lock pin.
1. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.
HINT:
2 advance side paths are provided in the groove of the camshaft. Plug one of the paths with a
rubber piece.
2. Break through the tape of the advance side path and the retard side path on the opposite side
to the hole of the advance side path, as shown in the illustration.
NOTE: Be careful not to damage the camshaft.

Fig. 221: Identifying Vinyl Tape Area
3. Apply approximately 200 kPa (2.0 kgf/cm2 , 28 psi) of air pressure to the two broken paths.
Fig. 222: Applying Air Pressure To Broken Paths
4. Check that the camshaft timing gear revolves in the advance direction when reducing the air
pressure applied to the retard side path.
HINT:
This operation releases the lock pin for the most retarded position.
CAUTION: Cover the paths with a shop rag or piece of cloth when
applying pressure to keep oil from splashing.

5. When the camshaft timing gear reaches the most advanced position, release the air pressure
from the retard side path and advance side path, in that order.
Fig. 223: Checking Camshaft Timing Gear Revolves In Advance Direction
h. Check for smooth rotation.
1. Turn the camshaft timing gear within its movable range (21°) 2 or 3 times, but do not turn it
to the most retarded position. Make sure that the gear turns smoothly.
i. Check the lock in the most retarded position.
1. Confirm that the camshaft timing gear is locked at the most retarded position.
j. Remove the fringe bolt and camshaft timing gear.
4. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY
a. Clamp the camshaft in a vise.
NOTE: Do not release the air pressure from the advance side path first.
The gear may abruptly shift in the retard direction and break the
lock pin.
CAUTION: Do not use air pressure to perform the smooth operation
check.
NOTE: l Be sure not to remove the other 3 bolts.
l If planning to reuse the gear, be sure to release the straight pin
lock before installing the gear.
NOTE: Be careful not to damage the camshaft in the vise.

Fig. 224: Identifying Fringe Bolt
b. Put the camshaft timing exhaust gear and camshaft together by aligning the key groove and straight
pin.
c. Lightly press the gear against the camshaft, and turn the gear. Push further at the position where the
pin enters the groove.
d. Check that there is no clearance between the gear's fringe and the camshaft.
Fig. 225: Aligning Key Groove And Straight Pin
e. Tighten the fringe bolt with the camshaft timing exhaust gear fixed.
Torque: 100 N*m (1,020 kgf*cm, 74 ft.*lbf)
f. Check the camshaft timing exhaust gear lock.
1. Make sure that the camshaft timing exhaust gear is locked.
CAUTION: Be sure not to turn the camshaft timing exhaust gear in the
retard direction (the right angle).

Fig. 226: Tightening Fringe Bolt With Camshaft Timing Exhaust Gear
g. Release the lock pin.
1. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.
HINT:
4 oil paths are provided in the groove. Plug 2 paths with rubber pieces.
2. Prick a hole in the tape placed on the advance side path. Prick a hole in the tape placed on the
retard side path, on the opposite side to that of the advance side path, as shown in the
illustration.
Fig. 227: Identifying Vinyl Tape Area

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